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Pressure Die Casting

Pressure die casting is a manufacturing process that utilizes high pressure to melt metal or forced molten metal into a steel mould (also name die) cavity. It is a precise and cost-effective casting method that suitable for these metal components that have tight tolerance requirement. Here at NICE Rapid, we have advanced equipment and machines that allows us to provide high quality product and best solution for your project.

Press die casting services

Pressure Die Casting Advantages

Compare to other process, die casting has a significant advantage in cost-effective savings, especially for some components that has complex structure. It includes below other advantages:

  • Excellent dimensional accuracy
  • Cast high strength sections within the structure directly
  • Good surface finish compared to other processes
  • Reduction in material scrap
  • Long too life – basically thousands to millions parts can be made from a mold before replacing

How Does Pressure Die Casting Work?

The principle of pressure die casting is to inject a molten metal alloy into a steel mold under high pressure, it will get solidified rapidly even from milliseconds to a few seconds to form the net shaped parts. It is then automatically extracted. This is the process of pressure die casting.

Working principle of pressure die casting

Pressure die casting can be divided into high pressure die casting and low pressure die casting two types upon different pressure used. High pressure die casting is normally categorized into two basic systems depending on whether the shot chamber is heated, see below chart to compare the difference.

Hot chamber system

Cold chamber system

Material

Zinc, magnesium

Aluminum, copper, magnesium

Heated

Yes

No

Pressure

This is suited to lower pressures, of up to 35 MPa, and low melting temperature alloys of zinc and magnesium.

Pressures can be as high as 150 MPa. This process is suited to higher melting point alloys of aluminum, magnesium and copper.

Process

The metal is held within the diecasting machine itself, then drawn into the chamber and forced into the mould by the injection piston.

The metal is first melted in a separate furnace and transferred to a holding furnace, then poured into a shot sleeve and injected into the mould.

Materials of Pressure Die Casting

Aluminum, magnesium and zinc are the most common types of metallic alloys used in die casting process.

1. Die Casting Alloys

Zinc: the easiest metal be casted. The melting state of zinc alloy is very fluidity, melting point is only 365 ℃.

Aluminum: good plasticity, can be processed into various profiles, with excellent electrical conductivity. 

Magnesium: Easy to be machined, high strength to weight ratio, the lightest of commonly used die casting metals.

2. Die Cast

Die casting molds must be made of hot die steel. There are some types of steel materials such as H13, 8407, 1.2344, 8418 are suitable. Typically, the H13 with Rockwell hardness of HRC42-48 is preferable.

Applications

Due to this unique range of characteristics, light metal can be used to cast complex, safety-critical components in automotive, electronics and aerospace. It also offers a cost-effective production option for simple parts from lighting components to kitchen tools.

  • Aerospace engine parts
  • Automotive parts
  • Kitchen tools
  • General hardware appliances, pump parts, plumbing parts

If you are interested in pressure die casting services and have a demand for making complex componets at low cost, we are kindred spirits on this sector. Feel free to let us know.


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